1.

General Description S510001

A: SPECIFICATIONS S510001E49
1. DRIVE PLATE AND DRIVEN PLATE S510001E4901
Plate number of high clutch
1.6 L 3
2.0 L 4
2.0 L TURBO 5
2.5 L 4
3.0 L 5
Plate number of reverse clutch
1.6 L 1
2.0 L 2
2.0 L TURBO 2
2.5 L 2
3.0 L 2
Plate number of 2-4 brake
1.6 L 2
2.0 L 3
2.0 L TURBO 4
2.5 L 3
3.0 L 4
Plate number of low clutch
1.6 L 4
2.0 L 4
2.0 L TURBO 7
2.5 L 6
3.0 L 7
Plate number of low and reverse brake
1.6 L 4
2.0 L 4
2.0 L TURBO 7
2.5 L 6
3.0 L 7
Plate number of transfer clutch
1.6 L 4
2.0 L 4
2.0 L TURBO (Without VTD) 6
2.0 L TURBO (With VTD) 3
2.5 L (Without VTD) 5
2.5 L (With VTD) 3
3.0 L (Without VTD) 6
3.0 L (With VTD) 3
2. AUTOMATIC TRANSMISSION FLUID
CAPACITY S510001E4902
Dexron III type Automatic transmission fluid
1.6 L, 2.0 L 8.4 8.7 (8.9 9.2 US qt, 7.4 7.7 Imp qt)
2.0 L TURBO, 2.5 L, 3.0 L 9.3 9.6 (9.8 10.1 US qt, 8.2 8.4 Imp qt)
3. FRONT DIFFERENTIAL OIL CAPACITY
S510001E4903
Recommended oil Oil capacity
GL-5 1.1 1.2 (1.2 1.3 US qt, 1.0 1.1 Imp qt)
AT-2
GENERAL DESCRIPTION
Automatic Transmission
MEMO:
AT-3
GENERAL DESCRIPTION
Automatic Transmission
B: COMPONENT S510001A05
1. TORQUE CONVERTER CLUTCH AND
CASE S510001A0501
B3M2273A
(1) Pitching stopper bracket
(2) O-ring
(3) Differential oil level gauge
(4) Stay (Except for Legacy)
(5) Seal pipe
(6) Seal ring
(7) Oil pump shaft
(8) Clip
(9) Oil drain pipe
(10) Input shaft
(11) O-ring
(12) Torque converter clutch ASSY
(13) Drain plug
(14) Gasket
(15) Oil seal
(16) Torque converter clutch case
(17) Stay (For Legacy)
Tightening torque: Nm (kgf-m, ft-lb)
T1: 18 (1.8, 13.0)
T2: 41 (4.2, 30.4)
T3: 44 (4.5, 32.5)
AT-4
GENERAL DESCRIPTION
Automatic Transmission
2. OIL PUMP S510001A0502
B3M2274A
(1) Oil pump rotor
(2) Oil pump cover
(3) Seal ring
(4) Thrust needle bearing
(5) Drive pinion shaft
(6) Roller bearing
(7) Shim
(8) Oil pump housing
(9) Nipple
(10) Air breather hose
(11) Gasket
(12) O-ring
(13) Test plug
(14) Stud bolt
(15) O-ring
(16) O-ring
(17) Oil seal retainer
(18) Oil seal
(19) O-ring
(20) Drive pinion collar
(21) Lock nut
Tightening torque: Nm (kgf-m, ft-lb)
T1: 7 (0.7, 5.1)
T2: 13 (1.3, 9.4)
T3: 18 (1.8, 13.0)
T4: 25 (2.5, 18.1)
T5: 40 (4.1, 30)
T6: 42 (4.3, 31)
T7: 116 (11.8, 85)
AT-5
GENERAL DESCRIPTION
Automatic Transmission
3. TRANSMISSION CASE AND CONTROL
DEVICE S510001A0503
B3M2267A
AT-6
GENERAL DESCRIPTION
Automatic Transmission
(1) ATF level gauge
(2) ATF charger pipe
(3) O-ring
(4) Transfer valve plate
(5) Transfer valve ASSY
(6) Transfer clutch seal
(7) Transfer duty solenoid
(8) Straight pin
(9) Return spring
(10) Shaft
(11) Parking pawl
(12) Parking support
(13) Inlet filter
(14) Gasket
(15) Inlet pipe (Except for Forester)
(16) Union screw
(17) O-ring
(18) Test plug
(19) Oil filter (Except 3.0 L model)
(20) Oil filter stud bolt
(21) Drain plug
(22) Gasket
(23) Oil pan
(24) Magnet
(25) Stud bolt (Short)
(26) Stud bolt (Long)
(27) Parking rod
(28) Manual plate
(29) Spring pin
(30) Detention spring
(31) Ball
(32) Spring
(33) Gasket
(34) Outlet pipe (For Forester)
(35) Union screw
(36) Oil seal
(37) Select lever
(38) Inhibitor switch ASSY
(39) Nipple
(40) Air breather hose
(41) Transmission case
(42) Plate ASSY
(43) Washer
(44) Outlet pipe (Except for Forester)
(45) O-ring (3.0 L model)
(46) Cover (3.0 L model)
(47) Gasket (3.0 L model)
(48) Union screw (3.0 L model)
(49) Inlet pipe (Except for Forester)
Tightening torque: Nm (kgf-m, ft-lb)
T1: 3.4 (0.35, 2.5)
T2: 5 (0.5, 3.6)
T3: 6 (0.6, 4)
T4: 8 (0.8, 6)
T5: 12 (1.2, 8.7)
T6: 13 (1.3, 10)
T7: 14 (1.4, 10)
T8: 18 (1.8, 13)
T9: 25 (2.6, 18)
T10: 44 (4.5, 32)
AT-7
GENERAL DESCRIPTION
Automatic Transmission
4. CONTROL VALVE AND HARNESS
ROUTING S510001A0504
B3M1833A
(1) Stay
(2) Transmission harness
(3) O-ring
(4) O-ring
(5) Torque converter turbine speed
sensor
(6) O-ring
(7) Front vehicle speed sensor
(8) O-ring
(9) Rear vehicle speed sensor
(10) Upper valve body
(11) Accumulator piston
(12) Accumulator spring
(13) Side plate
(14) Separate plate
(15) Middle valve body
(16) Separate plate
(17) Fluid filter
(18) Fluid filter
(19) Lower valve body
(20) Shift solenoid 2
(21) Shift solenoid 1
(22) 2-4 brake timing solenoid
(23) 2-4 brake duty solenoid
(24) ATF temperature sensor
(25) Line pressure duty solenoid
(26) Low clutch timing solenoid
(27) Lock-up duty solenoid
(28) Oil strainer
Tightening torque: Nm (kgf-m, ft-lb)
T1: 7 (0.7, 5.1)
T2: 8 (0.8, 5.8)
AT-8
GENERAL DESCRIPTION
Automatic Transmission
5. HIGH CLUTCH AND REVERSE CLUTCH
S510001A0505
S3M0221A
(1) High clutch drum
(2) Lip seal
(3) Lathe cut seal ring
(4) Reverse clutch piston
(5) Lathe cut seal ring
(6) Lathe cut seal ring
(7) High clutch piston
(8) Spring retainer
(9) Cover
(10) Snap ring
(11) Driven plate
(12) Drive plate
(13) Retaining plate
(14) Snap ring
(15) Dish plate
(16) Driven plate
(17) Drive plate
(18) Retaining plate
(19) Snap ring
(20) Thrust needle bearing
(21) High clutch hub
AT-9
GENERAL DESCRIPTION
Automatic Transmission
6. PLANETARY GEAR AND 2-4 BRAKE
S510001A0506
B3M1997A
(1) Thrust needle bearing
(2) Front sun gear
(3) Thrust needle bearing
(4) Snap ring
(5) Front planetary carrier
(6) Thrust needle bearing
(7) Rear sun gear
(8) Thrust needle bearing
(9) Rear planetary carrier
(10) Washer
(11) Thrust needle bearing
(12) Rear internal gear
(13) Washer
(14) Snap ring
(15) Retaining plate
(16) Drive plate
(17) Driven plate
(18) Pressure rear plate
(19) Snap ring
(20) Spring retainer
(21) 2-4 brake piston
(22) Lathe cut seal ring
(23) Lathe cut seal ring
(24) 2-4 brake piston retainer
(25) 2-4 brake seal
(26) Leaf spring
AT-10
GENERAL DESCRIPTION
Automatic Transmission
7. LOW CLUTCH AND LOW & REVERSE
BRAKE S510001A0507
B3M1017B
(1) Retaining plate
(2) Drive plate
(3) Driven plate
(4) Dish plate
(5) Snap ring
(6) Cover
(7) Spring retainer
(8) Lathe cut seal ring
(9) Low clutch piston
(10) Lathe cut seal ring
(11) Low clutch drum
(12) Needle bearing
(13) Inner snap ring
(14) One-way clutch
(15) Outer snap ring
(16) Thrust needle bearing
(17) Seal ring
(18) Needle bearing
(19) One-way clutch inner race
(20) Socket bolt
(21) Spring retainer
(22) Return spring
(23) Snap ring
(24) Retaining plate
(25) Leaf spring
(26) Drive plate
(27) Driven plate
(28) Dish plate
(29) Low and reverse brake piston
Tightening torque: Nm (kgf-m, ft-lb)
T: 25 (2.5, 18.1)
AT-11
GENERAL DESCRIPTION
Automatic Transmission
8. REDUCTION GEAR WITHOUT VTD
S510001A0508
B3M2189A
(1) Seal ring
(2) Ball bearing
(3) Reduction drive gear
(4) Reduction drive shaft
(5) Drive pinion shaft
(6) Snap ring
(7) Ball bearing
(8) Reduction driven gear
(9) Snap ring (Legacy 2.5 L US
model and 3.0 L model)
(10) Washer
(11) Lock nut
Tightening torque: Nm (kgf-m, ft-lb)
T: 100 (10.2, 73.8)
AT-12
GENERAL DESCRIPTION
Automatic Transmission
9. REDUCTION GEAR WITH VTD S510001A0509
B3M2275A
(1) Ball bearing
(2) Reduction drive gear
(3) Washer
(4) Needle bearing
(5) Pinion gear
(6) Carrier
(7) Planetary pinion shaft
(8) Snap ring
(9) Seal ring
(10) Thrust needle bearing
(11) Intermediate shaft
(12) Thrust washer
(13) Rear drive shaft
(14) Ball bearing
(15) Multi-plate clutch (LSD) hub
(16) Ball bearing
(17) Revolution gear
(18) Driven plate (Thicker)
(19) Drive plate
(20) Driven plate (Thinner)
(21) Driven plate (Thicker)
(22) Adjust plate
(23) Rear drive shaft shim
(24) Drive pinion shaft
(25) Snap ring
(26) Ball bearing
(27) Reduction driven gear
(28) Snap ring (Legacy 2.5 L US
model and 3.0 L model)
(29) Lock washer
(30) Lock nut
(31) Gasket
(32) Extension case
Tightening torque: Nm (kgf-m, ft-lb)
T: 100 (10.2, 73.8)
AT-13
GENERAL DESCRIPTION
Automatic Transmission
10. DIFFERENTIAL GEAR S510001A0510
B3M1019A
(1) Crown gear
(2) Pinion shaft
(3) Differential case (RH)
(4) Straight pin
(5) Differential case (LH)
(6) Taper roller bearing
(7) Oil seal
(8) O-ring
(9) Differential side retainer
(10) Circlip
(11) Lock plate
(12) Axle shaft
(13) Washer
(14) Differential bevel pinion
(15) Differential bevel gear
Tightening torque: Nm (kgf-m, ft-lb)
T1: 25 (2.5, 18.1)
T2: 62 (6.3, 45.6)
AT-14
GENERAL DESCRIPTION
Automatic Transmission
11. TRANSFER AND EXTENSION CASE
WITHOUT VTD S510001A0511
B3M2116B
(1) Thrust needle bearing
(2) Needle bearing
(3) Snap ring
(4) Pressure plate
(5) Drive plate
(6) Driven plate
(7) Pressure plate
(8) Snap ring
(9) Transfer piston seal
(10) Return spring
(11) Transfer clutch piston
(12) Rear drive shaft
(13) Ball bearing
(14) Seal ring
(15) Gasket
(16) Transfer clutch pipe
(17) Extension case
(18) Transmission hanger
(19) Oil seal
(20) Dust cover
(21) Test plug
(22) O-ring
(23) Clip
Tightening torque: Nm (kgf-m, ft-lb)
T1: 13 (1.3, 9.4)
T2: 25 (2.5, 18.1)
AT-15
GENERAL DESCRIPTION
Automatic Transmission
12. TRANSFER AND EXTENSION CASE
WITH VTD S510001A0512
B3M2276A
(1) Driven plate (Thicker)
(2) Drive plate
(3) Driven plate (Thinner)
(4) Driven plate (Thicker)
(5) Adjust plate
(6) Snap ring
(7) Spring retainer
(8) Plate
(9) Lathe cut seal ring
(10) Multi-plate clutch (LSD) piston
ASSY
(11) Lathe cut seal ring
(12) Gasket
(13) Multi-plate clutch (LSD) pipe
(14) Extension case
(15) O-ring
(16) Test plug
(17) Oil seal
(18) Dust cover
(19) O-ring
(20) Rear vehicle speed sensor
Tightening torque: Nm (kgf-m, ft-lb)
T1: 7 (0.7, 5.1)
T2: 13 (1.3, 9.4)
T3: 25 (2.5, 18.1)
AT-16
GENERAL DESCRIPTION
Automatic Transmission
C: PRECAUTION S510001F59
When disassembling or assembling the automatic
transmission, observe the following instructions.
1) Workshop
Provide a place that is clean and free from dust.
Principally the conventional workshop is suitable
except for a dusty place. In a workshop where
grinding work, etc. which produces fine particles is
done, make independent place divided by the vinyl
curtain or the equivalent.
2) Work table
The size of 1 x 1.5 m (40 x 60 in) is large enough
to work, and it is more desirable that its surface be
covered with flat plate like iron plate which is not
rusted too much.
3) Cleaning of exterior
(1) Clean the exterior surface of transmission
with steam and/or kerosene prior to
disassembly, however it should be noted that
vinyl tape be placed on the air breather or oil
level gauge to prevent infiltration of the steam
into the transmission and also the cleaning job
be done away from the place of disassembly
and assembly.
(2) Partial cleaning will do, depending on the
extent of disassembly (such as when disassem-
bly is limited to some certain parts).
4) Disassembly, assembly and cleaning
(1) Disassemble and assemble the transmis-
sion while inspecting the parts in accordance
with the Diagnostics.
(2) During job, do not use gloves. Do not clean
the parts with rags: Use chamois or nylon cloth.
(3) Pay special attention to the air to be used
for cleaning. Get the moisture and the dust rid
of the air as much as possible. Be careful not to
scratch or dent any part while checking for
proper operation with an air gun.
(4) Complete the job from cleaning to comple-
tion of assembly as continuously and speedily
as possible in order to avoid occurrence of sec-
ondary troubles caused by dust. When stopping
the job unavoidably cover the parts with clean
chamois or nylon cloth to keep them away from
any dust.
(5) Use kerosene, white gasoline or the equiva-
lent as washing fluid. Use always new fluid for
cleaning the automatic transmission parts and
never reuse. The used fluid is usable in disas-
semble and assemble work of engine and
manual transmission.
(6) Although the cleaning should be done by
dipping into the washing fluid or blowing of the
pressurized washing fluid, the dipping is more
desirable. (Do not rub with a brush.) Assemble
the parts immediately after the cleaning without
exposure to the air for a while. Besides in case
of washing rubber parts, perform the job quickly
not to dip them into the washing fluid for long
time.
(7) Apply the automatic transmission fluid
(ATF) onto the parts immediately prior to
assembly, and the specified tightening torque
should be observed carefully.
(8) Use vaseline if it is necessary to hold parts
in the position when assembling.
(9) Drain ATF and differential gear oil into a
saucer so that the conditions of fluid and oil can
be inspected.
(10) Do not support axle drive shaft, stator
shaft, input shaft or various pipes when moving
transmission from one place to another.
(11) Always discard old oil seals and O-ring,
and install new ones.
(12) Be sure to replace parts which are
damaged, worn, scratched, discolored, etc.
AT-17
GENERAL DESCRIPTION
Automatic Transmission
D: PREPARATION TOOL S510001A17
1. SPECIAL TOOLS S510001A1701
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B3M1977
398527700 PULLER ASSY Used for removing extension case roller
bearing.
Used for removing extension oil seal.
Used for removing front differential side
retainer bearing outer race.
B3M1972
498057300 INSTALLER Used for installing extension oil seal.
B3M1998
498077000 REMOVER Used for removing differential taper roller bear-
ing.
B3M1999
499247400 INSTALLER Used for installing transfer outer snap ring.
Used with GUIDE (499257300).
AT-18
GENERAL DESCRIPTION
Automatic Transmission
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B3M2000
499257300 SNAP RING OUTER
GUIDE
Used for installing transfer outer snap ring.
Used with INSTALLER (499247400).
B3M1953
499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
B3M2001
398437700 DRIFT Used for installing converter case oil seal.
B3M1912
398487700 INSTALLER Used for installing taper roller bearing of front
differential.
AT-19
GENERAL DESCRIPTION
Automatic Transmission
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B3M2002
398673600 COMPRESSOR Used for removing and installing clutch spring.
B3M1973
498255400 PLATE Used for measuring backlash of hypoid gear.
B3M2003
399893600 PLIERS Used for removing and installing clutch spring.
B3M1945
498247001 MAGNET BASE Used for measuring gear backlash.
Used with DIAL GAUGE (498247100).
AT-20
GENERAL DESCRIPTION
Automatic Transmission
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B3M1946
498247100 DIAL GAUGE Used for measuring gear backlash.
Used with MAGNET BASE (498247001).
B3M2004
498517000 REPLACER Used for removing front roller bearing.
B3M2005
498627100 SEAT Used for removing spring of transfer clutch pis-
ton.
B3M2006
499095500 REMOVER Used for removing axle shaft.
AT-21
GENERAL DESCRIPTION
Automatic Transmission
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B3M2007
499247300 INSTALLER Used for removing axle shaft.
Used with REMOVER (499095500).
B3M2008
499267300 STOPPER PIN Used for installing inhibitor switch.
B3M2009
499787700 WRENCH Used for removing and installing drive pinion
lock nut.
B3M2010
499787500 ADAPTER Used for removing and installing drive pinion
lock nut.
AT-22
GENERAL DESCRIPTION
Automatic Transmission
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B3M1978
398643600 GAUGE Used for measuring total end play, extension
end play and drive pinion height.
B3M2011
498627100 SEAT Used for holding low clutch piston retainer
spring when installing snap ring.
B3M2012
499577000 GAUGE Used for measuring the transmission case
mating surface to the reduction gear end sur-
face.
For without VTD.
B2M3854
398744300 GAUGE Used for measuring the transmission case
mating surface to the multi-plate clutch end sur-
face.
For with VTD.
AT-23
GENERAL DESCRIPTION
Automatic Transmission
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B3M2013
499737000 PULLER Used for removing reduction driven gear
assembly.
B3M2014
499737100 PULLER SET Used for removing reduction drive gear assem-
bly.
B3M2015
498077600 REMOVER Used for removing ball bearing.
B3M2016
498937110 HOLDER Used for removing and installing drive pinion
lock nut.
AT-24
GENERAL DESCRIPTION
Automatic Transmission
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B3M2017
498677100 COMPRESSOR Used for installing 2-4 brake snap ring.
B3M2018
498437000 HIGH CLUTCH PIS-
TON GUIDE
Used for installing high clutch piston.
B3M2018
498437100 LOW CLUTCH PIS-
TON GUIDE
Used for installing low clutch piston.
B3M2019
899580100 INSTALLER Used for press-fitting the ball bearing for trans-
fer clutch.
AT-25
GENERAL DESCRIPTION
Automatic Transmission
2. GENERAL PURPOSE TOOLS S510001A1702
TOOL NAME REMARKS
Depth gauge Used for measuring transmission end play.
Thickness gauge Used for measuring clearances of clutch, brake and oil pump.
Micro meter Used for measuring thickness of drive pinion.
Spring balance Used for measuring starting torque of drive pinion.
E: PROCEDURE S510001E45
In this section the procedures described under
each index are all connected and stated in order.
It will be the complete procedure for overhauling of
the automatic transmission itself when you go
through all steps in the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
AT-26
GENERAL DESCRIPTION
Automatic Transmission